Professional Documents
Culture Documents
for Cement
Alejandro Prez-Velzquez, Technical and R&D Manager, Jos-Francisco
Prez-Calvo, R&D Engineer, and Julin Martn Rubio, Production Manager,
Proquicesa, Spain.
Due to the current economic crisis and the situation in progress in the construction industry, Spanish
cement producers have been obliged to take several measures in order to notably reduce costs.
In light of this situation, Proquicesa decided to focus its R&D efforts on the development of an
innovative family of grinding aids, adapted to the new requirements of cement producers. In this way,
Proquicesa has maintained its commitment to offering adequate technical solutions to customers needs.
Thus, the company started an overall research project with the aim of finding new chemical
compounds that allowed it to reduce the economic significance of these kind of additives within total
cement production costs. Finally, at the end of 2008, Proquicesa introduced a new family of grinding
aids with an excellent cost/benefit ratio, called ADITOR M, which are formulated as an optimal
combination of some alternative raw materials.
Today, the ADITOR M are already being employed in several cement plants in Spain, and they
are also being tested at industrial scale in some other plants, generating excellent results with respect to
their technical performance and the economic savings obtained for the cement producers.
In this article, the most significant data and conclusions obtained from this research project are
shown, as well as some of the most significant results achieved in its industrial application.
Introduction
In the current worldwide economic situation, the
construction sector has been one of the most deeply
affected. In particular, cement production in Spain
decreased by 23% in 2008 relative to 2007.1 Due to this
huge drop and the forecast for the coming years, cement
producers feel obliged to take measures to drastically
reduce production costs.
One of the fields most affected by these cost-reducing
measures is the grinding aids sector, which has been
Al2O3
Fe2O3
CaO
MgO
SO3
SC
C3S
20.7
5.4
3.2
64.6
1.7
0.8
97.1
By Bogue calculation
Value
Speed (rpm)
55
Temperature
(C)
~ 90
Diameter (mm)
15 32
Ball-filling
volume fraction
(%)
~5
57.7
Grinding process
Balls/material
ratio (w/w)
Mass (kg)
36
Mass of CK +
Gyp (kg)
Ultrafine CK
addition (kg)
0.38
Grinding aid
dosage (ppm)
1000
Grinding time
(min)
60
Sampling time
(min)
15
R32 m (% wt)
Blank
ADITOR M1
ADITOR M2
ADITOR STD
90.0
90.0
90.0
90.0
30
59.4
47.1
52.8
42.2
45
35.5
21.7
20.7
30.3
60
18.4
10.1
7.8
11.7
Blaine (cm2/g)
GI (cm2/grev)
Blank
1.18 0.05
3163
0.96 0.04
ADITOR M1
1.37 0.05
3493
1.06 0.04
ADITOR M2
1.42 0.05
3518
1.07 0.04
ADITOR STD
1.29 0.05
3336
1.01 0.04
Additive
Grinding time
(min)
R32 m
(%)
Blaine
(cm2/g)
NC*
(%wt)
IST**
(min)
FST***
(min)
Blank
45
36.9
2331
28.0
230
270
60
24.2
2816
28.0
205
265
90
6.1
3770
29.0
185
225
120
2.5
4447
30.0
170
240
ADITOR M1
ADITOR M2
ADITOR STD
30
47.1
1991
28.0
180
205
45
21.7
2816
29.0
n/a
n/a
60
10.1
3493
29.0
160
190
90
3.2
4173
31.0
135
185
30
52.8
1840
28.4
205
255
45
20.7
2916
30.0
170
210
60
7.8
3518
31.0
155
195
90
2.2
4226
31.8
150
195
30
42.2
2046
28.0
195
225
45
30.3
2558
29.0
145
195
60
11.7
3336
29.0
160
185
90
3.1
4086
31.0
180
220
Blank
ADITOR M1
ADITOR M2
ADITOR STD
Grinding
time
(min)
2 days
7 days
28
days
45
6.4
11.4
29.6
40.5
60
11.9
22.7
36.1
47.8
90
19.8
30.5
41.9
55.0
120
24.5
32.3
45.9
52.1
30
6.4
15.2
29.2
37.2
45
13.9
23.8
35.9
47.7
60
18.2
28.1
41.1
48.4
90
20.8
32.0
43.1
52.6
30
5.1
11.8
23.0
31.2
45
16.1
23.1
34.5
45.4
60
21.2
30.0
40.9
51.0
90
22.8
31.2
42.6
53.1
30
6.6
14.9
28.4
37.9
45
12.3
20.4
33.4
37.9
60
16.7
25.3
40.9
49.6
90
19.8
31.3
40.5
47.4
Handling and
storage
Regulatory
information
Freezing
point
-10 C
< -20 C
-5 C
Boiling point
104 C
99 C
98 C
Flash point
Non
flammable
Non
flammable
Non
flammable
Chloride
content
Free (<0.1%
w/w)
Free (<0.1%
w/w)
Free (<0.1%
w/w)
Solubility in
water
Fully miscible
in all
proportions
Fully miscible
in all
proportions
Fully miscible
in all
proportions
Handling
Avoid contact
with eyes, skin
and clothes.
Use PPE
No other
requirements
Avoid contact
with eyes,
skin and
clothes. Use
PPE
Suitable
materials
Carbon steel,
stainless
steel, plastic
materials
Carbon steel,
stainless
steel, plastic
materials
Carbon steel,
stainless
steel, plastic
materials.
Avoid
aluminium
and cooper.
Risk symbols
Xi - Irritant
Xi - Irritant
Risk phrases
Safety
phrases
S26, S36
Nonhazardous
prepared
under the
applicable
legislation
Conclusions
From the results of the research project
carried out in Proquicesas pilot plant for the
development of ADITOR M, the following
conclusions can be underlined:
pH (20 C)
ADITOR
M1
ADITOR
M2
ADITOR
STD
ADITOR
M1
ADITOR
M2
ADITOR
STD
Average
1.154
1.124
1.061
8.09
7.93
7.57
Standard
deviation
(m)
0.001
0.003
0.001
0.86
0.85
0.11
H.T.L. (3 m)*
1.157
1.133
1.064
10.67
10.48
7.90
L.T.L. (3 m)1**
1.151
1.115
1.058
5.51
5.37
7.24
* H.T.L. (High Trust Limit) and L.T.L. (Low Trust Limit), calculated from the average
standard deviation threefold. These parameters indicate the maximum deviation
permitted by Proquicesas Quality Management System for each industrial batch
sample, and enable a decision on its storage and delivery. These are usually are
calculated one year after data collection.
Figure 6. Density and pH values of ADITOR M1, ADITOR M2 and ADITOR STD, collected from the last 20 weeks industrial batches.
commonly and
easily monitored
Aid Ref.*
ADITOR M
by Spanish cement
Type of cement** Dosage (g/Tm)
Dosage (g/Tm)
Rel. Price
Rel. Cost
Saving (%)
producers, as a
direct and simple
CEM I 52,5 R
800
300
0.67
0.25
75
standard of stability
CEM II/A-P 42,5 R 450
400
0.79
0.70
30
and quality of the
CEM II/B-P 32,5 N 350
350
0.65
0.65
35
product. Thus, the
CEM II/A-L 42,5 R 925
950
0.60
0.62
48
additives density
CEM II/B-L 32,5 N 900
925
0.58
0.60
40
and pH are the most
frequently used
BL I 52,5 R
350
350
0.53
0.53
47
quality standards in
I 42,5 R/SR
850
325
0.64
0.24
76
the cement industry.
*
The price of the regularly employed grinding aid and its cost were considered as a relative value of 1.00 in each case.
The values of
**
UNE-EN 197-1
density and pH of
the ADITOR M1,
z The new ADITOR M offered potential cost savings
ADITOR M2 and
50% higher than the traditional formulation.
ADITOR STD, collected from the last 20 weeks, are
shown in Figure 6. These values were obtained from the
Technical viability and quality control
analysis of the batches produced at industrial scale. Table
analysis
9 presents the statistical analysis of these data.
This stage of the project focused on the determination of
From the statistical analysis, it can be observed that
the technical viability of the production and marketing of
both ADITOR M and ADITOR STD densities had
similar reproducibilities (see the values of standard
the ADITOR M, under the strict controls of the quality
management system ISO 9001, implemented from 2001.
deviation in Table 9). However, the pH standard
For this reason, the physical-chemical properties
deviations of the ADITOR M were greater than the
normally used as technical specifications for grinding aids
deviation of the ADITOR STD. This can be due to the
were determined, as well as the hazardous classification
high amount of active matter (organic compounds)
and the recommended handling and storage conditions.
integrated in the composition of the ADITOR M. In this
way, the short quantity of free water incorporated in these
In the same way as before, these ADITOR M features
were compared to the properties of the traditional
formulations makes the pH an inaccuracy parameter.
grinding aid.
Thus, the variations on the pH are not representative of
the products composition stability.
Technical viability analysis: specifications
Today, Proquicesas Quality Department is working
and regulatory information
on the definition and development of new parameters
The study of the technical viability is a key issue in
and measuring techniques, which allow correct
the case of the ADITOR M, due to the employment
monitoring of the stability and quality of ADITOR M.
of byproducts from other industrial processes as raw
Furthermore, in order to guarantee the performance
materials for its production. For this reason, a complete
of the products in industrial applications, the Quality
characterisation of the new ADITOR M was required.
and R&D departments have developed a new validation
The main physical-chemical properties, regulatory
protocol for the product, which not only monitored the
information and handling and storage recommendations
physical-chemical properties of the additives produced
of the new additives are shown in Table 8. The
industrially, but also intensifies and improves the quality
information of ADITOR STD, as a reference of standard
control of the product, carrying out a periodic evaluation
traditional coadyuvants, is also presented. From this
of the additives performance in pilot grinding plant.
information, it can be observed that the employment
Molturation tests are routinely carried out in pilot plant
of subproducts of other industrial processes in the
mills to determine the coadjuvant power of the additive
composition of the ADITOR M did not have any
and its effect on the quality of the cement.
significant effect on either the physical-chemical
Industrial tests: validation stage
properties of the developed additive or the handling and
For industrial implementation of these new grinding
storage recommendations.
aids, some of the ADITOR M formulations were offered
Moreover, the employment of this type of byproduct
for testing in various cement plants in Spain. Specific
allowed the formulation of additives that have no
formulations were proposed in each case, depending on
hazardous classification by the current Spanish law. This
the different technical and/or economic situation of both
is an important advantage over the traditional additives,
the additive application and the type of cement produced.
such as ADITOR STD, which are usually classified as
In the first half of 2009, after eight months in the
irritant due to their composition.
market, different ADITOR M formulations have been
Quality control: parameters and monitoring
validated in 14 Spanish cement plants, which equates
Several physical-chemical properties are routinely
to some 30% of the total cement production facilities
analysed for each batch of grinding aid produced by
in the country. The results have encouraged a high
Proquicesa as a requirement of the companys quality
influx of the product into the Spanish market. At
managment system. Some of these parameters are
present, these products are being supplied to three of
Table 10. Cost savings realised with ADITOR M
Conclusion
The analysis of the results obtained from this study
demonstrates the technical and economic viability of the
formulations developed for the new family of additives in
the industrial cement grinding process.
From this work, the following conclusions can be
obtained:
z The formulations developed for the new low cost
grinding aids allowed the incorporation of chemical
products from other industrial processes into
the traditional composition of these aids. These
new formulations modified neither the chemical
stability or physical-chemical properties, nor their
hazardous classification or handling and storage
recommendations.
z The parameters and procedures followed for the
quality control guarantee its composition stability and
performance as a cement grinding aid.
z The industrial performance of ADITOR M
improved the results obtained by the traditional
aids, highlighting the selection and combination of
chemical products in its formulation.
References
1.
http://www.oficemen.com
2.
3.
4.
5.
6.
7.
8.
9.